Assembly Lines for R744 MAC Applications

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Applications

Speaker: Dipl Ing (FH) M Eismann ContiTech Fluid

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h A Speaker: Dipl. Ing. (FH) M. Eismann, ContiTech FluidHead of R&D Segment Air Conditioning

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Saalfelden 14´th february of 2008

Central R&D Segment Airconditioning

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Central R&D Segment Airconditioning

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Outline

Hot Gas Side: Metal Layer Hose

Connector: ContiLock R

Cold High Pressure and Suction Side Side: Polymeric Hose

Hot Gas Side: Metal Layer Hose

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2

Central R&D Segment Airconditioning

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What is the right concept?

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FEM Analyse for dimensioningA

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T=-40°C p=176bar T=20°C p=0bar T=20°C p=145bar T=180°C p=176bar

Central R&D Segment Airconditioning

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In Details

Female connectorConnection line-lineConnection line component

AssemblingPin/Hole combination

Easy mountingConnection line - component

ConturE i t ti i

Easy mounting Coding

Easy integration incomponents by machining

Loss protection Male connector

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Clipping plastic capHolds gasket on connectorEasy mountingDirt protection

Male connectorAluminium or SteelOuter dimension 42 x 21 x 18Inner dimension DN 4 to DN 9

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Gasket seal Screw-and-washer assy

Formed solution

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Spring metal corecoated with NBR

Screw and washer assyCr6 free (Geomet Plus VL)Torque 10,2 Nm class CM6 8.8x30

Central R&D Segment Airconditioning

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The sealing system of ContiLock R744

Stamping Hight

Flange

Seal between Flanges

Stamping Width

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FlangeTorque min: 10,2 – 20% =8,16Nm

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Flange

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FlangeTorque max: 10,2 + 20% =12,24Nm

Central R&D Segment Airconditioning

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6

R744 – ContiLock R Connector - Performance

Requirement Result

Tightnessg

Leakage test 0,5g/a 0,05g/a

Static tests

Torque resistance M ≥10Nm M >10NmTorque resistance MTorque ≥10Nm MTorque >10Nm

Tensile test FZug ≥ 3000N FZug > 4000N

Dynamic tests

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Vacuum test pAbs =0,5kPa, 5min Delta p =0,0kPa

Berst pressure t=180°C, p ≥ 34MPa P=34 – 40MPa

Pressure cycling durability 150.000, 17Mpa, t=-12-160°C no leakage

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Chemical tests

Corrosion Swaat EN ISO 9227, 20days no leakage

Corrosion salt spray test EN ISO 9227 24weeks no leakage

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Tec Corrosion salt spray test EN ISO 9227, 24weeks no leakage

Decompression

Decompression test 14MPa, 100°C, p to 0 in 10s no leakage

Central R&D Segment Airconditioning

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R744 – Hot gas line - Construction

Crimping

Pipe Stainless Steel 8x1

Connector Stainless SteelAluminium (coated)

Bending Radius rmin= 75mm

p gAluminium

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DN 06

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BraidSteel

Outer LayerHNBR

Inner LayerHNBR

Barrier LayerStainless Steel

Central R&D Segment Airconditioning

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8

R744 – Hot gas line - Performance

Requirement Result

Tightnessg

Leakage test 0,1g/a 0,0g/a

Static tests

Twisting capability M ≥6 5Nm t=165°C M >>6 5NmTwisting capability MTorque ≥6,5Nm, t=165 C MTorque >>6,5Nm

Flexural rigidity between 1,5 and 10N F=9N

Buckling & Deformation resistance ±0,5mm 0,10mm a. 0,14mm

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Tensile test F>2000N F=13266N

Change length & angle -1,5% to +2% / 2° 1% / 0,3°

Volume expansion <5% 0%

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Pressure cycling durability 150.000, 17Mpa, t=-12-160°C no leakage

Dynamic tests

Rotation 14MPa ±5 ±15mm 400U/min no leakage

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Tec Rotation 14MPa, ±5, ±15mm, 400U/min no leakage

Engine Rock 12Hz, ±10mm, ±15mm, 600tsd no leakage

Vibration test 107 cycles No leakage

Central R&D Segment Airconditioning

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9

R744 – Hot gas line - Performance

Requirement Result

Dynamic testsy

Burst pressure p=34MPa, t=180°C, 1min i.O. / 53MPa

Engine Rock 12Hz, ±10mm, ±15mm, 600tsd no leakage

Vibration test 107 cycles no leakageVibration test 107 cycles no leakage

Pressure cycling durability 150.000, 17Mpa, t=-12-160°C no leakage

Low temperature resistance -30°C, 20000c, 12Hz, ±12,5mm no leakage

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Chemical tests

Corrosion salt spray test EN ISO 9227, 24weeks no leakage, 25,5MPa

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R744 – Hot gas line – Outlook

Under Validation:

Aluminum pipes instead of stainless steelAluminum pipes, instead of stainless steel

easier crimping and assembling for the coupler

cost advantages when implementation of fillingcost advantages when implementation of filling . vales and sensors are required

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The „R744 Barrier Layer Polymere Hose“

Pipe Aluminium EN 5049 10,5 x 1,25Aluminium EN 5049 12,0 x 1,25

Connector Aluminium

CrimpingAluminium

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DiameterB di R di

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DN 08DN 10

Bending Radius rmin= 75mmrmin= 75mm

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BraidAramid

Outer LayerEPM

Barrier LayerTP

Inner LayerBIMS

Central R&D Segment Airconditioning

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Permeation Behavior Barrier Layer of the Polymer Hose

Example: Permeation Measurement at 7,0 MPa

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Permeation Behavior Barrier Layer of the Polymer HoseA

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R744 – Hot gas line - Performance

Requirement Result

Tightnessg

Static tests

Dynamic tests

Chemical testsChemical tests

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R744 – Component industrialization phase

LP DN10ContiLock R

Hot Gas St HP DN08

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Central R&D Segment Airconditioning

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AG

Thank you for your Attention!

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1

Central R&D Segment Airconditioning

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held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design registration.